Bond Surface Testing Apparatus and Method

ABSTRACT

A bond surface testing apparatus and method are presented. The bond surface testing apparatus comprises a solution chamber; a plurality of solution containers located in the solution chamber; a plurality of microfluidic pipettes; and an information capture module. Each solution container in the plurality of solution containers includes a microfluidic pipette in the plurality of microfluidic pipettes. A number of the plurality of microfluidic pipettes has a non-circular cross-section. The information capture module is physically associated with the solution chamber and is configured to capture information relating to bonding surface properties of the bonding surface.

CROSS REFERENCE TO RELATED APPLICATIONS

This application is a continuation-in-part of U.S. patent application Ser. No. 13/023,682 filed Feb. 9, 2011, status allowed, the entire disclosure of which is incorporated by reference herein.

TECHNICAL FIELD

The disclosure generally relates to apparatuses and methods for testing bonding suitability of structural composite bonding surfaces. More particularly, the disclosure generally relates to a bond surface testing apparatus and method capable of measuring characteristics of a bonding surface via surface energies that are activated on the bonding surface and then converted into a series of complex mathematical algorithms which output a calculated quality bonding factor that is based on the three-dimensional wettability surface energies of the bonding surface and indicates whether the bonding surface is suitable for bonding.

BACKGROUND

Currently, prepared structural composite bonding surfaces which are intended for structural bonding with another material are not certifiable prior to bonding. Thus, much expense may be wasted in scraps due to the poor bonding quality of bonding surfaces on composites. Conventional design and maintenance practices may not solely rely on the performance of a bonded joint or repair on composites for structural certification. As bonded composite structures become more common as a way to reduce weight and improve airframe performance in modern aircraft, reliable methods may be required to directly certify the quality of the bonded joints between composites without adding additional contaminants that may negate their structural benefits. In addition, the use of structural bonding repair techniques, compared to mechanically-fastened joints, may become more viable as a long-term repair solution. Like composite bonded structures, bonded repairs may require a certification method to ensure the structural quality of the bonding surfaces which form the bond between composites.

One current solution for ensuring that an optimum structural bond surface exists on a composite structure may rely on tight process controls and the skill of technicians to ensure quality and consistency. In some cases, cleanliness and roughness of the bonding surface may be measured and compared to an acceptable range to provide an inline process check. However, none of the known available methods can quantify and certify the bonding surface itself prior to structural bonding. Such a certification method would create confidence in the long-term durability of the bonded joint between composites after the structure which includes the bonded joint enters service. Individual surface characterization techniques that provide information on a single surface variable, such as surface roughness or active contaminants via profilometry or X-ray photoelectron spectroscopy (XPS), respectively, exist. However, both profilometry and XPS typical data may not quantify the structural bonding surface in terms of readiness to meet long-term structural joint durability, static strength and damage tolerance capability.

Conventional methods may not provide quantifiable engineering data related to the just-prepared structural bonding barrel surface quality or its bond durability. Moreover, such methods may not be compatible for localized use on the composite structures which are being bonded. Additionally, the existing techniques may not account for the potentially wide variations of the measured results on the structural bonding surface. Even a minimum of engineering data, such as surface roughness, for example, can vary greatly when the bonding surface is prepared per procedure via hand sanding methods, grit blasting, and laser techniques.

Therefore, a bond surface testing apparatus and method are needed which are capable of measuring characteristics of a bonding surface via surface energies that are activated on the bonding surface and then converted into a series of complex mathematical algorithms which output a calculated quality bonding factor that is based on the three-dimensional wettability surface energies of the bonding surface and indicates whether the bonding surface is suitable for bonding.

SUMMARY

In one illustrative embodiment, a bond surface testing apparatus for testing bonding suitability of a bonding surface is present. The bond surface testing apparatus comprises a solution chamber; a plurality of solution containers located in the solution chamber; a plurality of microfluidic pipettes; and an information capture module. Each solution container in the plurality of solution containers includes a microfluidic pipette in the plurality of microfluidic pipettes. A number of the plurality of microfluidic pipettes has a non-circular cross-section. The information capture module is physically associated with the solution chamber and is configured to capture information relating to bonding surface properties of the bonding surface.

In another illustrative embodiment, a bond surface testing apparatus for testing bonding suitability of a bonding surface is present. The bond surface testing apparatus comprises: a solution chamber, a plurality of solution containers located in the solution chamber, a plurality of microfluidic pipettes, a plurality of solutions in the solution chamber, a plurality of stand-offs, an information capture module, a data transfer pathway, a plurality of analysis modules, and a structural wettability factor prediction module. Each solution container in the plurality of solution containers includes a microfluidic pipette in the plurality of microfluidic pipettes. A number of the plurality of microfluidic pipettes has a non-circular cross-section. Each microfluidic pipette is configured to dispense a solution in the plurality of solutions onto the bonding surface. The plurality of stand-offs are configured to engage the bonding surface. The information capture module is carried by the plurality of stand-offs and configured to capture information relating to bonding surface properties of the bonding surface. The data transfer pathway interfaces with the information capture module. The plurality of analysis modules interfaces with the data transfer pathway and is configured to analyze the bonding surface properties of the bonding surface. The structural wettability factor prediction module interfaces with the data transfer pathway and is configured to predict a structural wettability factor based on the bonding surface properties.

In yet another illustrative embodiment, a bond surface testing method is presented. A plurality of solutions are provided. Functional groups on a bonding surface are activated by dispensing the plurality of solutions onto the bonding surface, in which at least one solution of the plurality of solutions is dispensed in a non-circular shape onto the bonding surface. The bonding surface properties on the bonding surface are analyzed. A structural wettability factor is predicted based on the bonding surface properties.

The features and functions can be achieved independently in various embodiments of the present disclosure or may be combined in yet other embodiments in which further details can be seen with reference to the following description and drawings.

BRIEF DESCRIPTION OF THE ILLUSTRATIONS

FIG. 1 is an exploded perspective view of an illustrative example of the bond surface testing apparatus;

FIG. 2 is a perspective view of an illustrative example of the bond surface testing apparatus;

FIG. 3A is an illustration of a perspective view of the bond surface testing apparatus and a composite structure tested for bonding production quality readiness;

FIG. 3B is a top view of a composite structure tested for bonding production quality readiness using solutions having non-circular shapes dispensed by an illustrative example of the apparatus;

FIG. 4 is a flow diagram of an illustrative example of the bond surface testing method;

FIG. 5 is a functional block diagram which illustrates operation of an illustrative example of the bond surface testing apparatus;

FIG. 5A is a flow diagram which summarizes an illustrative example of a bond surface testing method;

FIG. 5B is a flow diagram which illustrates operation of an illustrative example of the bond surface testing apparatus;

FIG. 6 is an illustration of a flow diagram of an aircraft production and service methodology; and

FIG. 7 is an illustration of a block diagram of an aircraft.

DETAILED DESCRIPTION

The following detailed description is merely exemplary in nature and is not intended to limit the described embodiments or the application and uses of the described embodiments. As used herein, the word “exemplary” or “illustrative” means “serving as an example, instance, or illustration.” Any implementation described herein as “exemplary” or “illustrative” is not necessarily to be construed as preferred or advantageous over other implementations. All of the implementations described below are exemplary implementations provided to enable persons skilled in the art to make or use the embodiments of the disclosure and are not intended to limit the scope of the embodiments of the disclosure which are defined by the claims. Furthermore, there is no intention to be bound by any expressed or implied theory presented in the preceding technical field, background, brief summary or the following detailed description.

The disclosure is generally directed to a bond surface testing apparatus which may activate surface energies of functional groups on a bonding surface and then analyze various chemical and mechanical bonding surface properties using a series of complex mathematical algorithms. When a solution activates a functional group on a bonding surface, the solution may interact with the functional group. This interaction may affect the behavior of the solution on the bonding surface. The functional groups which are activated may be those which are involved in bonding of the bonding surface with a second bonding surface. The apparatus may match the analyzed bonding surface properties of the bonding surface with three-dimensional wettability curves to determine convergence of the bonding surface properties with the three-dimensional wettability curves. Based on the convergence of the measured and analyzed bonding surface properties with the three-dimensional wettability curves, the apparatus may output a calculated quality bonding factor. The outputted quality bonding factor may indicate the bonding suitability of the bonding surface. Accordingly, the quality bonding factor may indicate whether the tested bonding surface on the structure is ready for production bonding or repair bonding with another structure or alternatively, whether the bonding surface requires preparation prior to bonding. In some applications, the quality bonding factor may be used to certify the bonding suitability of a bonding surface.

In some embodiments, the apparatus may be a portable handheld apparatus. The apparatus may be compact in design and utilized on a factory or shop floor for quick turnaround of both measurements of bonding engineering data and decisions related to the bonding suitability of a prepared structural composite surface for the operational life of the structure.

The apparatus may include integrated device components and process steps which may include multiple known solutions, for example, a complex solution chamber with multiple solution containers containing the known solutions and capable of dispensing the known solutions in predetermined volumes onto a bonding surface of a structure to activate surface energies of functional groups on the bonding surface as well as various analysis modules for analyzing bonding surface properties of the bonding surface. In some embodiments, the analysis modules of the apparatus may include a functional group analysis module for analyzing the functional groups on the bonding surface, a surface energy analysis module for analyzing the surface energies of the functional groups on the bonding surface, and a chemical-mechanical analysis module for computing the micro-chemical mechanics forces present on the bonding surface. The apparatus may further include a structural wettability factor (quality bonding factor) prediction module for prediction of the convergence of the three-dimensional wettability curves with the bonding surface properties which are based on the functional group analysis, the surface energy analysis and the chemical-mechanical characteristic analysis of the bonding surface, and a structural wettability factor printer for printing go/no-go quality bonding factor (Ø) which indicates bonding suitability based on the convergence of the three-dimensional wettability curves with the bonding surface properties.

Referring to FIGS. 1 and 2, an illustrative example of the bond surface testing apparatus, hereinafter apparatus, is generally indicated by reference numeral 100. The apparatus 100 may be used to determine the bonding suitability of a bonding surface (not shown) on a structural composite bonding element (not shown). In some applications, the structural composite bonding element may be a component of an aircraft fuselage, for example and without limitation. The apparatus 100 may be applicable to certification of the bonding surface of a structural composite bonding element in order to ensure the quality of structural bonds in which the structural composite bonding element is bonded to another bonding surface in production or repair of a structure.

As will be hereinafter further described, the apparatus 100 may be configured to contain and dispense solutions 128 having known chemical characteristics or properties onto a bonding surface 102 of a composite structure 101. The solutions 128 dispensed onto the bonding surface 102 of the composite structure 101 may activate surface energies of functional groups on the bonding surface 102. The functional groups which are activated on the bonding surface 102 may be the functional groups which would be involved in bonding of the bonding surface 102 to another bonding surface. The activated surface energies of the functional groups on the bonding surface 102 may substantially mimic the surface energies of the functional groups on the bonding surface, the bonding suitability of which is to be tested.

Using mathematical algorithms, the apparatus 100 may be configured to analyze bonding surface properties which may include analysis of the functional groups, the surface energies of the functional groups which are activated on the bonding surface 102 by the known solutions 128, and the micro-chemical mechanics forces present on the bonding surface 102. The apparatus 100 may be configured to predict convergence of three-dimensional wettability tension surface energy curves based on the analyzed bonding surface properties of the bonding surface 102 by matching the three-dimensional wettability curves to the bonding properties. The apparatus 100 may additionally be configured to formulate a bonding quality factor phi (Ø) which indicates bonding suitability based on the convergence of the three-dimensional wettability curves with the bonding properties. In some embodiments, the apparatus 100 may be configured to print the bonding quality factor (Ø).

The apparatus 100 may include a solution chamber 110. Multiple solution containers 111 may be provided in the solution chamber 110. The solution containers 111 may be arranged in adjacent relationship with respect to each other in the solution chamber 110. Each of the solution containers 111 may be configured to contain a known solution of solutions 128 which will be used to activate surface energies of chemical functional groups on a bonding surface 102 of a composite structure 101. Bonding surface properties which may include surface energies of the functional groups and the micro-chemical mechanics forces present on the bonding surface 102 may be analyzed and matched with three-dimensional wettability curves using mathematical algorithms. The apparatus 100 may be configured to predict the convergence of the three-dimensional wettability curves with the bonding surface properties. Based on the convergence of the three-dimensional wettability curves with the bonding surface properties, the apparatus 100 may be configured to predict the bonding suitability of a bonding surface on a structural composite bonding element (not shown) which is represented by the bonding surface 102 of the composite structure 101.

In some applications, the composite structure 101 may be a traveler element having the bonding surface 102 which mimics the bonding properties of the functional groups on the bonding surface being tested. Each of the solution containers 111 may include a microfluidic pipette and activator 112 which is configured to dispense a selected volume of the solutions 128 from the solution containers 111 onto the bonding surface 102. At least one of the shape of the dispensed solutions 128 and the material of the dispensed solutions 128 may affect the activation of the functional groups of the bonding surface 102.

As used herein, the phrase “at least one of,” when used with a list of items, means different combinations of one or more of the listed items may be used and only one of each item in the list may be needed. For example, “at least one of item A, item B, or item C” may include, without limitation, item A or item A and item B. This example also may include item A, item B, and item C or item B and item C. The item may be a particular object, thing, or a category. In other words, at least one of means any combination of items and number of items may be used from the list but not all of the items in the list are required.

As the shape of the dispensed solutions 128 may affect the activation of the functional groups of the bonding surface 102, changing the shape of the dispensed solutions 128 may change the activation of functional groups. Some shapes may be more effective at activating specific functional groups. Accordingly, a shape for a drop of the dispensed solutions 128 may be selected based on the composite material of composite structure 101. For example, the shape of the crystallinity of a composite structure 101 or the arrangement of functional groups of the composite structure 101 may influence a desired shape for a drop of the dispensed solutions 128.

In some examples, when composite structure 101 is an epoxy based composite, at least one of dispensed solutions 128 may have a square shape. In some examples, when composite structure 101 is a bismaleimide based composite, at least one of the dispensed solutions 128 may have a circular shape. In some examples, when composite structure 101 is a polyimide based composite, at least one of the dispensed solutions 128 may have an elliptical shape. In some examples, when composite structure 101 is a polyether ether ketone based composite, at least one of the dispensed solutions 128 may have a hexagonal shape. In some examples, when composite structure 101 is a poly either imide based composite, at least one of the dispensed solutions 128 may have an octagonal shape. In some examples, when composite structure 101 is a polycarbonate based composite, at least one of the dispensed solutions 128 may have a trapezoidal shape.

A shape of the dispensed solutions 128 may be influenced by the shape of the microfluidic pipette dispensing the fluid. For example, when the desired shape of the dispensed solutions 128 is non-circular, the cross-section of the microfluidic pipette may be non-circular. In some illustrative examples, at least one microfluidic pipette may be configured to dispense a solution as a droplet having a non-circular shape.

FIG. 3B is a top view of a composite structure tested for bonding production quality readiness using solutions having non-circular shapes dispensed by an illustrative example of the apparatus. As shown in FIG. 3B, dispensed solutions 128 have an elliptical shape.

Accordingly, the solutions 128 can be selectively dispensed from the solution containers 111 onto the bonding surface 102 to activate the known surface energies of the functional groups and create the micro-chemical mechanics forces present on the bonding surface 102 in a manner which corresponds to the surface energies and micro-chemical mechanics forces of the functional groups on the bonding surface which is to be tested.

The apparatus 100 may include an information capture module 116 in FIGS. 1-2. The information capture module 116 may be configured to capture information which relates to the bonding surface properties of the bonding surface 102. As depicted, the information capture module 116 is physically associated with the solution chamber. When one component is “physically associated” with another component, the association is a physical association in the depicted examples. For example, a first component may be considered to be physically associated with a second component by at least one of being secured to the second component, bonded to the second component, mounted to the second component, welded to the second component, fastened to the second component, or connected to the second component in some other suitable manner. The first component also may be connected to the second component using a third component. The first component may also be considered to be physically associated with the second component by being formed as part of the second component, extension of the second component, or both.

In some illustrative examples, the information capture module 116 may include a number of optical sensors. As used herein, “a number of” means one or more items. For example, a number of optical sensors is one or more optical sensors. In some of these examples, the information capture module 116 may include nano-functionalized optic sensors. Nano-functionalized optic sensors are sensors that comprise nano particles. Optical sensors having nanoparticles may have more desirable functionality. For example, optical sensors having nanoparticles may result in a better resolution in capturing contact angles.

In some illustrative examples, the information relating to the bonding surface properties of the bonding surface 102 may include a contact angle. In some examples, the information capture module 116 may capture a two-dimensional contact angle. A two-dimensional contact angle may comprise measurements from two different perspectives.

In some illustrative examples, a two-dimensional contact angle may include measurements of a droplet of one of the solutions 128 relative to the bonding surface 102. In one illustrative example, a two-dimensional contact angle may include a measurement from direction 134 of FIG. 1. As depicted, direction 134 of FIG. 1 is substantially perpendicular to the bonding surface 102. In another illustrative example, a two-dimensional contact angle may include a measurement from direction 136 of FIG. 1. As depicted, direction 136 of FIG. 1 is substantially parallel to the bonding surface 102.

In some illustrative examples, the information capture module 116 may capture information related to the shape of droplets of the solutions 128. Specifically, the information capture module 116 may capture information related to the shape of the droplets of the solutions 128 from direction 134 of FIG. 1.

Stand-offs (or support for forming a solution clearance gap) 117 in FIGS. 1-3B may interface with the information capture module 116. The stand-offs 117 may be configured to engage the composite structure 101 during operation of the apparatus 100.

A functional group analysis module 120, a surface energy analysis module 121, a chemical-mechanical analysis module 122, a structural wettability factor prediction module 123 and a structural wettability factor printer 124 in FIGS. 1-2 may interface with the information capture module 116 through a data transfer pathway 126 in FIG. 1. Data transfer pathway 126 is the medium used to provide communications links between various modules connected together within apparatus 100. Data transfer pathway 126 may include connections, such as wire, wireless communication links, or fiber optic cables. In some embodiments, a battery 125 in FIGS. 1-2 may interface with the structural wettability factor printer 124 and other components of the apparatus 100.

A set of the known solutions 128 may be developed for each of the structural composite bonding elements, the bonding suitability of which are to be tested using the apparatus 100. The solutions 128 may be developed according to previously-identified surface energies and wettability tension data of the bonding surfaces of the elements prior to bonding. For example and without limitation, structural bismaleimide (BMI) composite surface (primarily the BMI matrix material) have both dispersive, polar and modified luftiz acid-base surface energies on the structural composite bonding element which is to be bonded to another surface. Accordingly, the solutions 128 which are dispensed onto the bonding surface 102 may include chemical characteristics which impart the corresponding bonding surface properties (surface energies and micro-chemical mechanics forces) to the functional groups on the bonding surface 102. The apparatus 100 may computationally combine the structural BMI bonding surface properties of the functional groups with the matching wettability tension curves of the structural composite bonding element to formulate a quality bonding factor (Ø). The quality bonding factor (Ø) may indicate whether the prepared bonding surface of the element is ready to be bonded.

In application of the apparatus 100, the bonding surface 102 of the composite structure 101 may be treated with the solutions 128 with known chemistries relative to the surface energies of functional groups on the bonding surface of the structural composite bonding element which is to be tested. After treatment with the solutions 128, the bonding surface 102 may include activated functional groups. The activated functional groups may be similar to those functional groups used in bonding the composite structure 101 to another element. In some examples, the activated functional groups may be similar to those of the adhesive which is used to bond the composite structure 101 to another element.

The material of composite structure 101 may be selected from epoxides, bismaleimides, polimides, polyether ether ketone, polyehterimides, polysulfone, polycarbonate, or other suitable composite materials. When composite structure 101 is an epoxide composite, the solutions will be selected to activate the epoxide functional group. When composite structure 101 is a bismaleimide composite, the solutions will be selected to activate the maleimide functional group. When composite structure 101 is a polyimide composite, the solutions will be selected to activate the imide functional group. When composite structure 101 is a polyether ether ketone composite, the solutions will be selected to activate the ketone functional group. When composite structure 101 is a polyetherimide composite, the solutions will be selected to activate the etharimide functional group. When composite structure 101 is a polysulfone composite, the solutions will be selected to activate the sulfone functional group. When composite structure 101 is a polycarbonate composite, the solutions will be selected to activate the carbonate functional group.

In some applications of the apparatus 100, the composite structure 101 may be a composite test specimen (or commonly known as a traveler element) which is prepared under identical conditions as the structural composite bonding element which is to be tested. Accordingly, the composite structure 101 may be selectively removed from the apparatus 100 for further analysis after implementation of the apparatus 100.

The functional group analysis module 120, the surface energy analysis module 121, the chemical-mechanical analysis module 122, and the structural wettability factor prediction module 123 of the apparatus 100 may utilize mathematical algorithms to analyze the bonding surface properties of the bonding surface 102 and formulate a structural wettability or bonding quality factor (Ø) which may be used to determine whether the bonding surface 102 is suitable for forming quality bonding with a structural element in production or repair applications. The analysis may be carried out using known principles of polymer chemistry. The functional group analysis module 120 may capture identification of the bonding functional groups which each of the solutions 128 impart to the bonding surface 102.

Surface tension measurements for formulation of the wettability prediction factor (bonding quality factor) on the bonding surface 102 may be analyzed by the functional group analysis module 120 of the apparatus 100 using equations E1a, E1b, E2a, E2b, E3, E4 and E5. The surface tension measurements may be the contact angle of a drop of a solution on the bonding surface 102.

Equation (E1a) is a modified version of Young's equation. Equation (E1a) may be used to calculate surface energy in surface energy analysis module 121. Equation (E1a) below accounts for the effect of adsorption of chemical species to the bonding surface 102 on the solid-vapor interface and liquid-vapor interface:

ΔG ₁ ^(G)=−γ_(lv)(1+cos ⊖)  E1a:

where,

-   -   ΔG₁ ^(G)=change in surface energy     -   γ_(lv)=surface tension of the liquid     -   ⊖=contact angle of the liquid

In some illustrative examples, the measurements may be a two-dimensional contact angle. When the measurements are a two-dimensional contact angle, the Young's equation may be further modified to equation (E1b) receive both measurements of the two-dimensional contact angle.

γ_(sv)=γ_(s)−π_(sg)=γ_(lv) cos ⊖+γ_(sl)+γ_(lg) +λt

where,

-   -   π_(sg)=equilibrium spreading pressure of the gaseous phase on         the solid substrate     -   γ_(sv)=surface tension of the solid vapor interface     -   γ_(s)=surface tension of the solid     -   γ_(lv)=surface tension of the liquid vapor interface     -   ⊖=contact angle taken from a direction normal to the composite         structure; such as direction 134 of FIG. 1     -   γ_(sl)=surface tension of the solid liquid interface     -   γ_(lg)=surface tension of the gaseous liquid interface     -   λ_(t)=a transverse interfacial contact angle taken from a         direction parallel to the composite structure, such as direction         136 of FIG. 1

Equations (E2a) and (E2b) may also be used by surface energy analysis module 121. Equations (E2a) and (E2b) below describe the equilibrium film pressure of a composite structure, the contact angle of which is less than zero.

γ_(s)−γ_(sv)=Π_(⊖sv)  E2a:

γ_(l)−γ_(lv)=Π_(⊖lv)  E2b:

where,

-   -   Π_(⊖sv)=equilibrium spreading pressure of the solid vapor         interface     -   Π_(⊖lv)=equilibrium spreading pressure of the liquid vapor         interface     -   γ_(s)=surface tension of the solid     -   γ_(sv)=surface tension of the solid in equilibrium with the         vapor     -   γ_(l)=surface tension of the liquid     -   γ_(lv)=surface tension of the liquid in equilibrium with the         vapor

The equilibrium spreading pressures above may be included in equation (E3) below representing the solid-liquid interface. Equation (E3) may be used by functional group analysis module 120.

γ_(s)−Π_(⊖sv)−γ_(sl)=(γ_(l)−Π_(⊖lv))cos_(⊖)  E3:

where,

-   -   Π_(⊖sv)=equilibrium spreading pressure of the solid vapor         interface     -   Π_(⊖lv)=equilibrium spreading pressure of the liquid vapor         interface     -   γ_(s)=surface tension of the solid     -   γ_(sl)=surface tension of the solid liquid interface     -   γ_(l)=surface tension of the liquid

The Wenzel equation (equation E4 below) may be used to describe the combined influence of hysteresis to measure the accurate contact angle where Ω is the ratio of the supposed area to the prepared area outer plane and ⊖ is the contact angle of the liquid on the bonding surface 102. In the Wenzel equation, two composite substrates may be provided: a first, roughened solid which has received surface processing, and a second solid which has not received surface processing.

Ω=cos_(⊖)/cos_(⊖′)  E4:

where,

-   -   Ω=a roughness factor     -   ⊖=contact angle that the liquid makes with a roughened surface         of a solid     -   ⊖′=contact angle made by the liquid with a surface of a solid

A modified Fox-Zisman equation may be used by chemical-mechanical analysis module 122. The inclusion of a modified Fox-Zisman equation, equation (E5), in analyzing the accuracy of the contact angle ⊖ is important in that the equation provides a more accurate estimate of γ_(s) of the composite structure to be bonded from the plot of ⊖ (contact angle) vs. the surface energies. This relationship may approximate a straight line described by equation (E5) below. In equation (E5), W_(I) represents a relevant factor of the Lifshitz equation without incorporating the entirety of the Lifshitz equation.

cos_(⊖)=1−b(γ_(l)−γ_(c))W _(I)  E5:

where,

-   -   W_(I)=thermodynamic work of adhesion at the slope intercept     -   ⊖=contact angle     -   γ_(c)=critical surface tension     -   γ_(l)=surface tension of the liquid     -   b=slope

As depicted above, γ_(c) is combined with γ_(l) and a relevant factor of the modified Lifshitz equation to yield a combined surface energy that is a consequence of both electromagnetic interactions and contact angle measurements from the Fox-Zisman equation. The modified Lifshitz equation may be expressed as:

γ_(SL)=γ_(S)+γ_(L)+γ_(V)−2(γ^(P) _(S)*γ^(P) _(L)*γ^(P/2) _(VS))

where,

-   -   γ^(P) _(S)=polar component of the solid     -   γ^(P) _(L)=polar component of the liquid     -   γ^(P) _(vs)=polar component of vapor and gaseous phase

The surface energy analysis module 121 of the apparatus 100 may capture identification of the bonding functional groups of each of the solutions 128 on the bonding surface 102 from the functional group analysis module 120 and compute the surface tensions of the functional groups as was heretofore described. These data may be transmitted to the computational chemical-mechanical analysis module 122, which may compile the data and predict three-dimensional wettability curves for the bonding surface 102. The structural wettability factor prediction module 123 may predict a wettability curve factor by comparing the previously-computed bonding surface properties of the functional groups activated by the solutions 128 to the predicted three-dimensional structural wettability curves computed by the chemical-mechanical analysis module 122. The structural wettability factor prediction module 123 may use the wettability curve factor to determine the bonded repair or bonded structure quality in the form of a bonding quality factor phi (Ø). The structural wettability factor printer 124 may print the bonding quality factor (Ø).

The use of the molecular theory of contact angle in a polar system, which is well-developed in polymer chemistry, can be combined to estimate the surface energy of the composite bonded structure mathematically by cohesive energies of the two phases. Composite structure and the wettability tensions of the adhesive system can be combined with the polar solutions to develop the individual surface energies close to the individual adhesive systems for bonding with the structural composite as shown in the cohesive energy equation in equation (6) below:

ΔG _(ij) =√{square root over (Δ)}G _(i) ⁰ −ΔG _(j) ⁰=−2√γ_(i)γ_(j) −ΔG _(ij) ^(a) /√{square root over (Δ)}G _(i) ^(c) ΔG _(j) ^(c)=1

where liquids i and j are both polar and

-   -   ΔG_(ij)=change in free surface energy for the two polar liquids,         i and j     -   √{square root over (Δ)}G_(i) ⁰=change in individual polar free         energy for liquid i     -   ΔG_(j) ⁰=change in individual polar free energy for liquid j     -   γ_(i)=surface tension of liquid i     -   γ_(j)=surface tension of liquid j     -   ΔG_(ij) ^(a)=initial change in individual polar free energy for         liquids i and j     -   ΔG_(i) ^(c)=initial change in polar free energy of the composite         structure of liquid i     -   ΔG_(j) ^(c)=initial change in polar free energy of the composite         structure of liquid j

Equation (6) may then be used to predict the composite structural surface energy and the adhesive wettability tensions to form predicted three-dimensional curves for the particular composite structures type. The resultant computed experimental exponent is provided as equation (7) and equation (8):

Ø(exp)=(γ_(i)+γ_(j−)γ_(ij))/2√(γ_(i)γ_(j))  E7:

ΔG _(ij) ^(a)/√(ΔG _(i) ⁰ ΔG _(j) ⁰)=Ø  E8:

where,

-   -   γ_(ij)=combined surface tensions for liquids i and j

These thermodynamic cohesion processes and thermodynamic adhesion processes represent the idealization of free surface energy models employing thermodynamic terms of:

ΔG=2γ−w ^(c).

where ΔG ^(C)=−2γ=−w ^(c); and,

where ΔG _(ij)=−γ_(ij)−γ_(i−)γ_(j) =−w _(ij) ^(c)

Referring to FIG. 4, a flow diagram 400 which illustrates an illustrative example of the bond surface testing method is shown. The method may be carried out in implementation of the apparatus 100 which was heretofore described with respect to FIGS. 1 and 2. In block 402, the solution chamber 110 of the apparatus 100 dispenses known solutions 128 onto a bonding surface 102 of a composite structure 101. In block 404, the functional group analysis module 120 of the apparatus 100 may identify functional groups which the solutions 128 activate on the bonding surface 102. In block 406, the structural surface energy analysis module 121 of the apparatus 100 may analyze surface tensions and pressures on the bonding surface 102. In block 408, the chemical-mechanical analysis module 122 of the apparatus 100 may predict three-dimensional wettability curves based on the bonding surface property data obtained from the functional group analysis module 120 and the surface energy analysis module 121. In block 410, the structural wettability factor prediction module 123 of the apparatus 100 may predict a bonding quality factor by matching the surface energies of the functional groups on the bonding surface with the three-dimensional wettability curves.

In the event that the bonding quality factor predicted in block 410 is less than one (block 412), the method may return to block 402. In the event that the bonding quality factor predicted in block 410 is greater than one (block 414), durable bonding is achievable and production is ready in block 416. In block 418, the structural wettability factor printer 124 of the apparatus 100 may print out quality control parameters for the structure to be bonded.

Referring next to FIGS. 1-3A and 5, a functional block diagram 500 which illustrates exemplary operation of an illustrative example of the bond surface testing apparatus 100 is shown in FIG. 5. In block 502, the stand-offs 117 (FIGS. 1 and 2) of the apparatus 100 may be adjusted on the bonding surface 102 of the composite structure 101. In some applications, the stand-offs 117 may be a distance allowing the solution to clear the surface tension. In block 504, the apparatus 100 may be located on the bonding surface 102. The wettability tension device may be placed next to stand-offs 117 to minimize surface contact and optimize separation. The stand-offs 117 may be adjusted to minimize surface contact and optimize separation on the bonding surface 102. In block 506, the apparatus 100 may be activated. Accordingly, a micro-liter volume of each solutions 128 may be deposited from each of the solution containers 111 of the solution chamber 110 onto the bonding surface 102. In block 508, after all solutions 128 have been deposited onto the bonding surface 102, the apparatus 100 may initiate an analytical mode 509 in which surface measurement images are taken with an onboard camera (not shown). As shown in FIG. 3A, in some applications, onboard LEDs 132 may illuminate the bonding surface 102. FIG. 3A is a view within section 3-3 of FIG. 2. As depicted, onboard LEDs 132 are carried by information capture module 116. In some other examples, onboard LEDs 132 may be attached to a different module of the apparatus 100.

As shown in FIG. 5, in some embodiments, the analytical mode 509 may include operation of the solution chamber 110 to deposit the solutions 128 onto the bonding surface 102 (block 510); functional group identification by the functional group analysis module 120 (block 512); structural surface energy analysis by the structural surface energy analysis module 121 (block 514); computation of three-dimensional wettability curves by the chemical-mechanical analysis module 122 (block 516) based on the functional group analysis and the structural surface energy analysis; prediction of a wettability curve or bonding quality factor by the structural wettability factor prediction module 123 (block 518); and printing of the structural wettability factor with certifiable results by the structural wettability factor printer 124 (block 520). The certifiable results may indicate whether the surface is ready for bonding or surface preparation is required prior to bonding.

If the structural wettability factor predicted in block 518 and printed in block 520 is less than one, the method may return (block 522) to block 502 and blocks 504-520 may be repeated. If the structural wettability factor is greater than one, the method may proceed to block 524 in which durable bonding is achievable and bonding production can proceed.

Referring next to FIG. 5A, a flow diagram 500A which summarizes an illustrative example of the bond surface testing method is shown. In block 502A, known solutions are provided. If a composite structure 101 to be tested is an epoxide composite, a solution may be dimethyl sulfur oxide. If composite structure 101 to be tested is a bismaleimide (BMI) composite, a solution may be a non-fluorinated compound. For other types of composite structure 101, a solution may be a fluorinated compound. In block 504A, functional groups on a bonding surface are activated by dispensing the solutions onto the bonding surface. In block 506A, bonding surface properties on the bonding surface are analyzed. In some embodiments, analyzing bonding surface properties may include identifying functional groups on the bonding surface. In some embodiments, analyzing bonding surface properties may include analyzing surface energies on the bonding surface. In some embodiments, analyzing bonding surface properties may include predicting three-dimensional wettability curves based on the bonding surface properties. In block 508A, a structural wettability factor is predicted based on the bonding surface properties. In some embodiments, predicting a structural wettability factor based on the bonding surface properties may include predicting a structural wettability factor by matching the three-dimensional wettability curves with the surface energies on the bonding surface.

Referring next to FIG. 5B, a flow diagram 500B which illustrates operation of an illustrative example of the bond surface testing apparatus is shown. In block 502B, the method begins by providing a plurality of solutions. In block 504B, the method may activate functional groups on a bonding surface by dispensing the plurality of solutions onto the bonding surface, in which at least one solution of the plurality of solutions is dispensed in a non-circular shape onto the bonding surface. In block 506B, the method may analyze bonding surface properties on the bonding surface. In some embodiments, analyzing bonding surface properties may include identifying functional groups on the bonding surface. In some embodiments, analyzing bonding surface properties may include analyzing surface energies on the bonding surface. In some embodiments, analyzing bonding surface properties may include predicting three-dimensional wettability curves based on the bonding surface properties. In block 508B, the method may predict a structural wettability factor based on the bonding surface properties. In some embodiments, predicting a structural wettability factor based on the bonding surface properties may include predicting a structural wettability factor by matching the three-dimensional wettability curves with the surface energies on the bonding surface. Afterwards the process may terminate.

Referring next to FIGS. 6 and 7, embodiments of the disclosure may be used in the context of an aircraft manufacturing and service method 78 as shown in FIG. 6 and an aircraft 94 as shown in FIG. 7. During pre-production, exemplary method 78 may include specification and design 80 of the aircraft 94 and material procurement 82. During production, component and subassembly manufacturing 84 and system integration 86 of the aircraft 94 takes place. Thereafter, the aircraft 94 may go through certification and delivery 88 in order to be placed in service 90. While in service by a customer, the aircraft 94 may be scheduled for routine maintenance and service 92 (which may also include modification, reconfiguration, refurbishment, and so on).

Each of the processes of method 78 may be performed or carried out by a system integrator, a third party, and/or an operator (e.g., a customer). For the purposes of this description, a system integrator may include, without limitation, any number of aircraft manufacturers and major-system subcontractors; a third party may include, without limitation, any number of vendors, subcontractors, and suppliers; an operator may be an airline, leasing company, military entity, service organization, and so on.

As shown in FIG. 7, the aircraft 94 produced by exemplary method 78 may include an airframe 98 with a plurality of systems 96 and an interior 103. Examples of high-level systems 96 include one or more of a propulsion system 105, an electrical system 104, a hydraulic system 106, and an environmental system 108. Any number of other systems may be included. Although an aerospace example is shown, the principles of the invention may be applied to other industries, such as the automotive industry.

The apparatus embodied herein may be employed during any one or more of the stages of the production and service method 78. For example, components or subassemblies corresponding to production process component and subassembly manufacturing 84 may be fabricated or manufactured in a manner similar to components or subassemblies produced while the aircraft 94 is in service. In other words, composite structure 101 in FIG. 1 may be used to form a component or subassembly during production process component and subassembly manufacturing 84. The bonding surface 102 in FIG. 1 of composite structure 101 may be tested during production process component and subassembly manufacturing 84. Also one or more apparatus embodiments may be utilized during the production stages material procurement 82 and system integration 86, for example to test bonding surface 102 of composite structure 101. Use of one or more apparatus or method embodiments may expedite assembly of or reduce the cost of an aircraft 94. Similarly, one or more apparatus embodiments may be utilized while the aircraft 94 is in service, for example and without limitation, during maintenance and service 92. For example, the apparatus or method embodiments may be used to test the bonding surface 102 of a replacement or repair composite structure 101 during maintenance and service 92.

The disclosure is generally directed to a bond surface testing apparatus for testing bonding suitability of a bonding surface. An illustrative embodiment of the apparatus includes a solution chamber; a plurality of solutions in the solution chamber, the solution chamber configured to dispense the solutions onto the bonding surface; an information capture module carried by the solution chamber and configured to capture information relating to bonding surface properties of the bonding surface; at least one analysis module interfacing with the information capture module and configured to analyze the bonding surface properties of the bonding surface; and a structural wettability factor prediction module interfacing with the at least one analysis module and configured to predict a structural wettability factor based on the bonding surface properties.

In some embodiments, the bond surface testing apparatus may include a solution chamber; a plurality of solutions in the solution chamber, the solution chamber configured to dispense the solutions onto the bonding surface; a pair of stand-offs configured to engage the bonding surface; an information capture module carried by the stand-offs and configured to capture information relating to bonding surface properties of the bonding surface; a data transfer pathway interfacing with the information capture module; a plurality of analysis modules interfacing with the data transfer pathway and configured to analyze the bonding surface properties of the bonding surface; and a structural wettability factor prediction module interfacing with the data transfer pathway and configured to predict a structural wettability factor based on the bonding surface properties.

The disclosure is further generally directed to a bond surface testing method. An illustrative embodiment of the method includes providing a plurality of solutions; activating functional groups on a bonding surface by dispensing the plurality of solutions onto the bonding surface; analyzing bonding surface properties on the bonding surface; and predicting a structural wettability factor based on the bonding surface properties.

In one illustrative example, a bond surface testing apparatus for testing bonding suitability of a bonding surface is presented. The bond surface testing apparatus comprises a solution chamber; a plurality of solutions in the solution chamber, the solution chamber configured to dispense the solutions onto the bonding surface; an information capture module carried by the solution chamber and configured to capture information relating to bonding surface properties of the bonding surface; at least one analysis module interfacing with the information capture module and configured to analyze the bonding surface properties of the bonding surface; and a structural wettability factor prediction module interfacing with the at least one analysis module and configured to predict a structural wettability factor based on the bonding surface properties.

In some examples, the apparatus further comprises a structural wettability factor printer interfacing with the structural wettability factor prediction module and configured to print the structural wettability factor. In some examples, the apparatus further comprises a plurality of solution containers in the solution chamber and wherein the plurality of solutions are contained in the plurality of solution containers, respectively. In some examples, the apparatus further comprises a plurality of solution containers in the solution chamber and wherein the plurality of solutions are contained in the plurality of solution containers, respectively; and a plurality of microfluidic pipettes and actuators interfacing with the plurality of solution containers, respectively, and be configured to dispense the solutions onto the bonding surface. In some examples, the at least one analysis module comprises a functional group analysis module configured to identify functional groups on the bonding surface. In some examples, the at least one analysis module comprises a functional group analysis module configured to identify functional groups on the bonding surface and the at least one analysis module comprises a surface energy analysis module configured to analyze surface energies of the functional groups on the bonding surface. In some examples, the at least one analysis module comprises a functional group analysis module configured to identify functional groups on the bonding surface; the at least one analysis module comprises a surface energy analysis module configured to analyze surface energies of the functional groups on the bonding surface; and the at least one analysis module comprises a chemical-mechanical analysis module configured to predict three-dimensional wettability curves based on data from the functional group analysis module and the surface energy analysis module. In some examples, the at least one analysis module comprises a functional group analysis module configured to identify functional groups on the bonding surface; the at least one analysis module comprises a surface energy analysis module configured to analyze surface energies of the functional groups on the bonding surface; the at least one analysis module comprises a chemical-mechanical analysis module configured to predict three-dimensional wettability curves based on data from the functional group analysis module and the surface energy analysis module; and the structural wettability factor prediction module configured to predict the structural wettability factor by matching the three-dimensional wettability curves with the surface energies of the functional groups on the bonding surface.

In another illustrative example, a bond surface testing apparatus for testing bonding suitability of a bonding surface is presented. The bond surface testing apparatus comprises a solution chamber; a plurality of solutions in the solution chamber, the solution chamber configured to dispense the solutions onto the bonding surface; a pair of stand-offs configured to engage the bonding surface; an information capture module carried by the stand-offs and configured to capture information relating to bonding surface properties of the bonding surface; a data transfer pathway interfacing with the information capture module; a plurality of analysis modules interfacing with the data transfer pathway and configured to analyze the bonding surface properties of the bonding surface; and a structural wettability factor prediction module interfacing with the data transfer pathway and configured to predict a structural wettability factor based on the bonding surface properties.

In some examples, the apparatus further comprises a structural wettability factor printer interfacing with the data transfer pathway and configured to print the structural wettability factor In some examples, the apparatus further comprises a plurality of solution containers in the solution chamber and wherein the plurality of solutions are contained in the plurality of solution containers, respectively. In some examples, the apparatus further comprises a plurality of solution containers in the solution chamber wherein the plurality of solutions are contained in the plurality of solution containers, respectively, and a plurality of microfluidic pipettes and actuators interfacing with the plurality of solution containers, respectively, and configured to dispense the solutions onto the bonding surface.

In some examples, the plurality of analysis modules comprises a functional group analysis module configured to identify functional groups on the bonding surface. In some examples, the plurality of analysis modules comprises a functional group analysis module configured to identify functional groups on the bonding surface; and wherein plurality of analysis modules comprises a surface energy analysis module configured to analyze surface energies of the functional groups on the bonding surface. In some examples, the plurality of analysis modules comprises a functional group analysis module configured to identify functional groups on the bonding surface; wherein plurality of analysis modules comprises a surface energy analysis module configured to analyze surface energies of the functional groups on the bonding surface; and wherein the plurality of analysis modules comprises a chemical-mechanical analysis module configured to predict three-dimensional wettability curves based on data from the functional group analysis module and the surface energy analysis module. In some examples, In some examples, the plurality of analysis modules comprises a functional group analysis module configured to identify functional groups on the bonding surface; wherein plurality of analysis modules comprises a surface energy analysis module configured to analyze surface energies of the functional groups on the bonding surface; wherein the plurality of analysis modules comprises a chemical-mechanical analysis module configured to predict three-dimensional wettability curves based on data from the functional group analysis module and the surface energy analysis module; and wherein the structural wettability factor prediction module is configured to predict the structural wettability factor by matching the three-dimensional wettability curves with the surface energies of the functional groups on the bonding surface.

In one illustrative example, a bond surface testing method is presented. The method comprises providing a plurality of solutions; activating functional groups on a bonding surface by dispensing the plurality of solutions onto the bonding surface; analyzing bonding surface properties on the bonding surface; and predicting a structural wettability factor based on the bonding surface properties. In some examples, the analyzing bonding surface properties comprises identifying functional groups on the bonding surface. In some examples, the analyzing bonding surface properties comprises identifying functional groups on the bonding surface and analyzing surface energies on the bonding surface. In some examples, the analyzing bonding surface properties comprises identifying functional groups on the bonding surface, analyzing surface energies on the bonding surface, and predicting three-dimensional wettability curves based on the bonding surface properties.

A bond surface testing apparatus includes a solution chamber; a plurality of solutions in the solution chamber, the solution chamber configured to dispense the solutions onto a bonding surface; an information capture module carried by the solution chamber and configured to capture information relating to bonding surface properties of the bonding surface; at least one analysis module interfacing with the information capture module and configured to analyze the bonding surface properties of the bonding surface; and a structural wettability factor prediction module interfacing with the at least one analysis module and configured to predict a structural wettability factor based on the bonding surface properties.

Although the embodiments of this disclosure have been described with respect to certain exemplary embodiments, it is to be understood that the specific embodiments are for purposes of illustration and not limitation, as other variations will occur to those of skill in the art. 

What is claimed is:
 1. A bond surface testing apparatus for testing bonding suitability of a bonding surface, comprising: a solution chamber; a plurality of solution containers located in the solution chamber; a plurality of microfluidic pipettes, wherein each solution container in the plurality of solution containers includes a microfluidic pipette in the plurality of microfluidic pipettes and wherein a number of the plurality of microfluidic pipettes has a non-circular cross-section; and an information capture module physically associated with the solution chamber and configured to capture information relating to bonding surface properties of the bonding surface.
 2. The bond surface testing apparatus of claim 1, wherein the information relating to the bonding surface properties of the bonding surface comprises a two-dimensional contact angle.
 3. The bond surface testing apparatus of claim 1, wherein the information capture module comprises a number of optical sensors.
 4. The bond surface testing apparatus of claim 1 further comprising: at least one analysis module interfacing with the information capture module and configured to analyze the bonding surface properties of the bonding surface; and a structural wettability factor prediction module interfacing with the at least one analysis module and configured to predict a structural wettability factor based on the bonding surface properties.
 5. The bond surface testing apparatus of claim 4, wherein the at least one analysis module comprises a functional group analysis module configured to identify functional groups on the bonding surface.
 6. The bond surface testing apparatus of claim 5, wherein the at least one analysis module further comprises a surface energy analysis module configured to analyze surface energies of the functional groups on the bonding surface.
 7. The bond surface testing apparatus of claim 6, wherein the at least one analysis module further comprises a chemical-mechanical analysis module configured to predict three-dimensional wettability curves based on data from the functional group analysis module and the surface energy analysis module.
 8. The bond surface testing apparatus of claim 7, wherein the structural wettability factor prediction module is configured to predict the structural wettability factor by matching the three-dimensional wettability curves with the surface energies of the functional groups on the bonding surface.
 9. A bond surface testing apparatus for testing bonding suitability of a bonding surface, comprising: a solution chamber; a plurality of solution containers located in the solution chamber; a plurality of microfluidic pipettes, wherein each solution container in the plurality of solution containers includes a microfluidic pipette in the plurality of microfluidic pipettes and wherein a number of the plurality of microfluidic pipettes has a non-circular cross-section; a plurality of solutions in the solution chamber, each microfluidic pipette configured to dispense a solution in the plurality of solutions onto the bonding surface; a plurality of stand-offs configured to engage the bonding surface; an information capture module carried by the plurality of stand-offs and configured to capture information relating to bonding surface properties of the bonding surface; a data transfer pathway interfacing with the information capture module; a plurality of analysis modules interfacing with the data transfer pathway and configured to analyze the bonding surface properties of the bonding surface; and a structural wettability factor prediction module interfacing with the data transfer pathway and configured to predict a structural wettability factor based on the bonding surface properties.
 10. The bond surface testing apparatus of claim 9, wherein the information relating to the bonding surface properties of the bonding surface comprises a two-dimensional contact angle.
 11. The bond surface testing apparatus of claim 9, wherein the information capture module comprises a number of optical sensors.
 12. The bond surface testing apparatus of claim 9, wherein the plurality of analysis modules comprises a functional group analysis module configured to identify functional groups on the bonding surface.
 13. The bond surface testing apparatus of claim 12, wherein the plurality of analysis modules further comprises a surface energy analysis module configured to analyze surface energies of the functional groups on the bonding surface.
 14. The bond surface testing apparatus of claim 13, wherein the plurality of analysis modules comprises a chemical-mechanical analysis module configured to predict three-dimensional wettability curves based on data from the functional group analysis module and the surface energy analysis module.
 15. The bond surface testing apparatus of claim 14, wherein the structural wettability factor prediction module is configured to predict the structural wettability factor by matching the three-dimensional wettability curves with the surface energies of the functional groups on the bonding surface.
 16. A bond surface testing method, comprising: providing a plurality of solutions; activating functional groups on a bonding surface by dispensing the plurality of solutions onto the bonding surface, in which at least one solution of the plurality of solutions is dispensed in a non-circular shape onto the bonding surface; analyzing bonding surface properties on the bonding surface; and predicting a structural wettability factor based on the bonding surface properties.
 17. The bond surface testing method of claim 16 further comprising: capturing information relating to the bonding surface properties of the bonding surface, wherein the information relating to the bonding surface properties of the bonding surface comprises a two-dimensional contact angle.
 18. The bond surface testing method of claim 16, wherein analyzing the bonding surface properties comprises identifying the functional groups on the bonding surface.
 19. The bond surface testing method of claim 18, wherein analyzing the bonding surface properties further comprises analyzing surface energies on the bonding surface.
 20. The bond surface testing method of claim 19, wherein analyzing the bonding surface properties further comprises predicting three-dimensional wettability curves based on the bonding surface properties. 